Platinum Metals Rev.

, 2011, 55, (1), 2027

The Role of Process Parameters in

Platinum Casting
Investigation of optimised casting parameters for two platinum jewellery alloys

doi:10.1595/147106711X540373 http://www.platinummetalsreview.com/

By Ulrich E. Klotz* and Tiziana Drago
The Research Institute for Precious Metals and
Metals Chemistry (FEM), Katharinenstrasse 17,
D-73525 Schwbisch Gmnd, Germany;
*E-m
mail: klotz@fem-o
online.de
Platinum is a challenging material for casters because
of its physical properties, which result in possible cru-
cible and flask reactions during melting and casting,
high shrinkage porosity and difficulties in filling of
filigree items. This paper summarises the results of a
collaborative research effort by several industrial part-
ners and FEM on the influence of casting process
parameters. Two common platinum jewellery alloys
(platinum with 5 wt% cobalt and platinum with 5 wt%
ruthenium) and four different investment materials
were used for casting experiments with variation of
atmosphere, casting and flask temperature, tree design
and centrifugal machine parameters. Detailed sample
investigation found shrinkage porosity and surface
defects to be the main problems. Optimised process
parameters for heavy and filigree items were identi-
fied. Future research on platinum casting should focus
on casting simulation in order to reduce experimental
effort and costs.

Introduction
In recent years articles on the casting properties of
platinum have been published (1, 2). Different
aspects such as suitable alloys for casting (36), tree
design (710) and investment reactions (11, 12) have
been discussed, as well as the effect of centrifugal
casting parameters for different alloys and invest-
ments (1214). Platinum with 5 wt% cobalt (Pt-5Co)
was identified as a very versatile casting alloy,
showing excellent form filling of filigree parts even
for flask temperatures as low as 100C (12). Platinum
with 5 wt% ruthenium (Pt-5Ru) on the other hand
showed poor form filling of filigree parts for flask
temperatures below 800C (12). Besides casting pro-
perties, functional alloy properties such as colour,
hardness, ductility and magnetic properties have to
be taken into account for jewellery. In this regard
Pt-5Ru is more versatile compared to Pt-5Co or plat-
inum with 5 wt% copper (Pt-5Cu), and can be used
for all jewellery applications.

20 2011 Johnson Matthey

doi:10.1595/147106711X540373
The present project focused on Pt-5Ru and Pt-5Co
as the most commonly used jewellery alloys.
Investment casting experiments were carried out as
part of a research project commissioned by Platinum
Guild International (PGI), USA, in cooperation with
several industrial partners and FEM. This paper sum-
marises the results given in a presentation at the 24th
Santa Fe Symposium on Jewelry Manufacturing
Technology in 2010 (15).
Experimental
Casting experiments were carried out using a TopCast
TCE10 vacuum centrifugal casting machine with
induction heating and a power of 10 kW and a work-
ing capacity of 1500 g. Metal temperature during
heating and melting was monitored using a quotient
pyrometer. Most of the casting trees used a diablo
type setup. A typical tree containing some standard
items (ball rings and grid) is shown in Figure 1. Four
different investments from different suppliers were
tested. Table I gives an overview of the properties of
the investments and briefly describes the experience
of working with them.
A number of casting experiments were carried out
to analyse the influence of casting parameters (melt
temperature, flask temperature, casting atmosphere,
casting machine type), alloy and investment material
by using standard sample geometries such as ball
rings and grids. The grid represents filigree items and
demonstrates form filling ability. The ball ring repre-
sents heavy section pieces. With the large ball acting
as a hotspot it was expected to provoke investment
reactions and to be prone to shrinkage porosity.
90
0
Centrifugal
direction 270
21
Platinum Metals Rev., 2011, 55, (1)
The as-cast samples were evaluated in terms of
surface quality, shrinkage porosity and investment
reactions by optical microscopy, metallography and
scanning electron microscopy (SEM).
Results and Discussion
Alloy Properties
The alloys differ in their dendrite morphology,segrega-
tion behaviour and melting temperature. Solidus and
liquidus temperature were calculated using the
Thermo-Calc software package with the Scientific
Group Thermodata Europe (SGTE) noble metal alloys
database (SNOB1), and are in accordance with
Reference (16). The calculated phase diagrams give
the same melting range for both alloys, but due to seg-
regation the melting range of Pt-5Co is actually about
twice that of Pt-5Ru.This is one possible reason for the
better form filling ability of Pt-5Co. However, segrega-
tion of Co to the melt promotes oxidation of Co and
investment reactions, even for vacuum casting.
Form Filling
Form filling is a critical issue for filigree items and was
determined on standard grids (Figure 2). Pt-5Co
clearly has superior form filling ability to that of
Pt-5Ru and shows excellent results for a flask temper-
ature of 850C. For Pt-5Ru, form filling considerably
increases with increasing centrifugal speed and flask
temperature. Its optimum flask temperature is 950C
for filigree items. Vacuum casting allowed complete
filling of filigree items with two-part investments for
both alloys, as did overheating of the melt for Pt-5Ru.
However, this also promoted investment reactions.
Fig. 1. Example of typical casting tree design
with diablo type setup
180
2011 Johnson Matthey
22
Table I
Properties of Investments Used in the Platinum Alloy Casting Trials
doi:10.1595/147106711X540373

Investment Manufacturers Type Base and Mixing Working Burnout Burnout Remarks
brand name liner time, min time, min time, h temperature, C

No. 1 R&R Platinum Two-part Paper base 30 1012 12.5 871 Curing does not start at room
and liner temperature, extended working
time possible

No. 2 Lane PT120 Two-part Paper base 2025 1012 12.0 870 Curing does not start at room
and liner temperature, extended working
time possible

No. 3 Gold Star Platin One-part/ Rubber base 8 57 11.5 900 Cold water required to reach
Cast fibre upper working time limit; high
viscosity

No. 4 SRS Platin One-part/ Rubber base 8 57 10.0 900 Cold water required to reach
fibre upper working time limit; high
viscosity, risk of bending of filigree
parts, especially plastic parts

2011 Johnson Matthey

Platinum Metals Rev., 2011, 55, (1)
doi:10.1595/147106711X540373 Platinum Metals Rev., 2011, 55, (1)

Fig. 2. Grid filling as

function of flask temperature
100 for air casting of Pt-5Co and
Pt-5Ru (except value for
550C). Averaged values
80 of all grids per tree
Grid fill, %

60

40

20 Average Pt-5Ru
Average Pt-5Co
0
500 600 700 800 900 1000
Flask temperature, C

Surface of Cast Parts Investment inclusions (Figure 4) on the surface

The surface quality of cast parts is affected by invest-
ment reactions, inclusions of investment particles and
rough or matt appearing surfaces. Table II compares
the behaviour of the two alloys using the different
investments at different flask temperatures.
The best surface quality was observed for Pt-5Ru.
This alloy did not show any investment reactions
despite its high casting temperature. Investment
reactions were observed for Pt-5Co independent of
casting atmosphere and resulted in a blue layer of
cobalt silicate (Figure 3).
were observed, especially in the case of the one-part
investment No. 4. With increasing flask temperature
the surface became rougher and the inclusions
more frequent. For the two-part investments No. 1 and
No. 2, inclusions were seldom observed, probably
due to their lower porosity and higher stability.
Therefore, the surface quality achieved using these
investments was usually superior to that obtained
with investment No. 4.
The cast parts often showed matt and glossy areas.
The matt areas showed a dendritic-like surface and

Table II
Cobalt and Platinum-R
Devesting Performance and Surface Quality for Air Casting of Platinum-C Ruthenium
Alloysa

Investment Devesting Surface quality of Pt-55Co Surface quality of Pt-55Ru

performance alloy at the flask alloy at the flask
temperature, C temperature, C

850 950 1050 850 950 1050

No. 1 + ++ ++ n/a +++ +++ n/a

No. 2 +++ ++ ++ + ++(+) ++(+) +
No. 3b ++ +++ +++ n/a + (cracks) + (cracks) n/a
No. 4 ++ + + n/a + + n/a
a
+++ (best); ++ (medium); + (worst)
b
No. 3 was only used for casting trials with Indutherm MC 15 tilting machine

23 2011 Johnson Matthey

doi:10.1595/147106711X540373 Platinum Metals Rev., 2011, 55, (1)

(a)

10 m

(b) (c)
O
O
Co

Co

Co
Co
Pt Si
Mg Mg
C P
Pt Pt Co C Co
Pt
0 1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8

Fig. 3. (a) Investment reactions of Pt-5Co (flask temperature 850C); (b) and (c) energy dispersive X-ray (EDX)
analysis of reaction products on position 1 (cobalt oxide) and position 2 (cobalt-magnesium silicate)

Fig. 4. Inclusions of investment

material (black) on the surface of
Pt-5Ru alloy

100 m

24 2011 Johnson Matthey

doi:10.1595/147106711X540373 Platinum Metals Rev., 2011, 55, (1)

were observed on the heavy sections (Figure 5) of the
affected parts. The matt surface was caused by shrink-
age of isolated melt volumes during solidification.
Shrinkage Porosity
Shrinkage porosity was the main problem for both
heavy bulk and lightweight filigree patterns in the
casting trials performed. The effects of casting para-
meters and the position on the tree were found to be
relatively small.
Table III and Table IV show shrinkage porosity in
the Pt-5Co and Pt-5Ru alloys, respectively. In general,
shrinkage porosity was less pronounced for Pt-5Ru.
There was a significant difference in shrinkage pore
morphology between the two alloys. Pt-5Co showed
few but large pores while Pt-5Ru often showed scat-
tered pores built by intersecting dendrites (Figure 6).
Flask temperature and casting atmosphere had lit-
tle influence. The investment material was found to
influence shrinkage porosity and the lowest levels
were achieved with investment No. 4. This is probably
an effect of the lower thermal conductivity of this
investment, resulting in slower and more homoge-
neous cooling of the melt.
Effect of the Casting Machine
A comparison of two types of casting machine, a cen-
trifugal (TopCast TCE10) and a tilting machine
(Indutherm MC 15, capacity 200 g), showed that cen-
trifugal casting produced superior results for form fill-
ing of filigree items. Defect-free castings of the ball ring
were obtained for the Pt-5Co alloy at 950C under vac-
uum using the tilting machine, which was not possible
by centrifugal casting under comparable conditions.

Fig. 5. Matt surface of a Pt-5Ru casting

with dendritic surface

100 m

Table III Table IV

Shrinkage Porosity in Metallographic Sections of Shrinkage Porosity in Metallographic Sections of
Ruthenium Alloya
Platinum-R Cobalt Alloya
Platinum-C

Flask Casting Investment Flask Casting Investment

temperature, C atmosphere temperature, C atmosphere
No. 1 No. 2 No. 4 No. 1 No. 2 No. 4

850 Air n/a ++ +++ 850 Air + + +

950 Air ++ ++ +++ 950 Air + + +
850 Vacuum + n/a n/a 850 Vacuum + n/a n/a
950 Vacuum ++ n/a n/a 950 Vacuum + n/a n/a
a a
+++ (low = best); ++ (high = medium); +++ (low = best); ++ (high = medium);
+ (very high = worst) + (very high = worst)

25 2011 Johnson Matthey

doi:10.1595/147106711X540373
(a)
2 mm
Fig. 6. Different morphologies of shrinkage porosity in the sphere of a ball ring: (a) Pt-5Co; (b) Pt-5Ru
Pt-5Ru was difficult to cast in the tilting machine,
because of the low heating rate in the specific model
used, which resulted in hot tearing of the parts.
Machines with higher power and sufficiently short
melting time may enable successful casting of Pt-5Ru.
Conclusions
In this study shrinkage porosity was found to be the
main problem for both bulk and filigree casting pat-
terns using Pt-5Ru and Pt-5Co alloys. The best results
in terms of shrinkage porosity were obtained with
Pt-5Ru alloy using investment No. 4.
In order to solve the problem of shrinkage porosity,
sprue design and tree setup are most important. Direc-
tional solidification has to be assured. The usefulness
of techniques such as increasing the flask temperature
is limited by the thermal stability of the investment
materials. However, optimisation of casting behaviour
solely by experimental means remains challenging.
Recommendations for Future Work
In recent years, casting simulation has been demon-
strated to be a valuable tool for gold and silver casting
(17, 18). Sophisticated software packages are avail-
able to determine form filling and shrinkage porosity
depending on alloy, tree setup, melt and flask temper-
ature, allowing optimisation by computer simulation.
This would be especially valuable for optimising the
casting parameters for platinum due to its high price
and extreme casting and flask temperatures.
Detailed knowledge of the thermophysical prop-
erties of the alloys and investments are required.
Such data are currently scarce and they must be
26
Platinum Metals Rev., 2011, 55, (1)
(b)
2 mm
determined. Benchmark experiments with sophis-
ticated thermal recording during the centrifugal
casting process should be performed to calibrate the
casting simulation results.
Investment materials were found to play an impor-
tant role in form filling and shrinkage porosity. It is
assumed that properties such as gas permeability and
thermal conductivity are responsible for this behav-
iour. Therefore, the influence of the water:powder
ratio, burnout cycle, flask temperature and casting
atmosphere requires further investigation to under-
stand how the physical properties of the investments
can be tailored.
Acknowledgements
The authors are grateful for the financial support of
PGI, with special thanks to Jurgen Maerz. C. Hafner
GmbH and Co, Germany, provided platinum alloys,
which is kindly acknowledged. The companies
Ransom & Randolph, USA, Lane Industries LLC, USA,
and Specialist Refractory Services Ltd (SRS) UK, are
acknowledged for providing investment materials
and Indutherm GmbH, Germany, is acknowledged for
casting trials. Special thanks to Dieter Ott (FEM,
Germany) for fruitful discussions of the project results
and to the staff members of the metallurgy depart-
ment at FEM, especially to Franz Held and Ulrike
Schindler for casting trials and metallography.
References
1 N. Swan, Jewellery in Britain, 2004, (19), 5
2 N. Swan, Platinum Metals Rev., 2007, 51, (2), 102
2011 Johnson Matthey
doi:10.1595/147106711X540373
3 G. Ainsley, A. A. Bourne and R. W. E. Rushforth, Platinum
Metals Rev., 1978, 22, (3), 78
4 J. Huckle, The Development of Platinum Alloys to
Overcome Production Problems, in The Santa Fe
Symposium on Jewelry Manufacturing Technology 1996,
ed. D. Schneller, Proceedings of the 10th Symposium in
Albuquerque, New Mexico, USA, 19th22nd May, 1996,
Met-Chem Research Inc, Albuquerque, New Mexico, USA,
1996, pp. 301326
5 J. Maerz, Platinum Alloy Applications for Jewelry, in
The Santa Fe Symposium on Jewelry Manufacturing
Technology 1999, ed. D. Schneller, Proceedings of the
13th Symposium in Albuquerque, New Mexico, USA,
16th19th May, 1999, Met-Chem Research Inc,
Albuquerque, New Mexico, USA, 1999, pp. 5572
6 J. Maerz, Platinum Alloys: Features and Benefits, in
The Santa Fe Symposium on Jewelry Manufacturing
Technology 2005, ed. E. Bell, Proceedings of the
19th Symposium in Albuquerque, New Mexico, USA,
22nd25th May, 2005, Met-Chem Research Inc,
Albuquerque, New Mexico, USA, 2005, pp. 303312
7 J. Maerz, Casting Tree Design and Investing Technique for
Platinum Induction Casting, in The Santa Fe Symposium
on Jewelry Manufacturing Technology 2002, ed. E. Bell,
Proceedings of the 16th Symposium in Albuquerque,
New Mexico, USA, 19th22nd May, 2002, Met-Chem
Research Inc, Albuquerque, New Mexico, USA, 2002,
pp. 335352
8 A. Nooten-Boom II, Controlled Flow = Controlled
Solidification, in The Santa Fe Symposium on Jewelry
Manufacturing Technology 2004, ed. E. Bell, Proceedings
of the 18th Symposium in Albuquerque, New Mexico,
USA, 23rd26th May, 2004, Met-Chem Research Inc,
Albuquerque, New Mexico, USA, 2004, pp. 315344
9 A. Nooten-Boom II, Dynamics of the Restricted Feed Tree,
in The Santa Fe Symposium on Jewelry Manufacturing
Technology 2006, ed. E. Bell, Proceedings of the 20th
Symposium in Nashville, Tennessee, USA, 10th13th
September, 2006, Met-Chem Research Inc, Albuquerque,
New Mexico, USA, 2006, pp. 387419
10 J. Maerz, Platinum Casting Tree Design, in The Santa
Fe Symposium on Jewelry Manufacturing Technology
2007, ed. E. Bell, Proceedings of the 21st Symposium
in Albuquerque, New Mexico, USA, 20th23rd May,
2007, Met-Chem Research Inc, Albuquerque, New Mexico,
USA, 2007, pp. 305322
11 H. Frye, M. Yasrebit and D. H. Sturgis, Basic Ceramic
Considerations for the Lost Wax Processing of High
Melting Alloys, in The Santa Fe Symposium on Jewelry
Manufacturing Technology 2000, ed. E, Bell, Proceedings
of the 14th Symposium in Albuquerque, New Mexico,
USA, 21st24th May, 2000, Met-Chem Research Inc,
Albuquerque, New Mexico, USA, 2000, pp. 101116
12 P. Lester, S. Taylor and R. Sss, The Effect of Different
Investment Powders and Flask Temperatures on the
Casting of Pt Alloys, in The Santa Fe Symposium on
27
Platinum Metals Rev., 2011, 55, (1)
Jewelry Manufacturing Technology 2002, ed. E. Bell,
Proceedings of the 16th Symposium in Albuquerque,
New Mexico, USA, 19th22nd May, 2002, Met-Chem
Research Inc, Albuquerque, New Mexico, USA, 2002,
pp. 321334
13 D. Miller, T. Keraan, P. Park-Ross, V. Husemeyer and
C. Lang, Platinum Metals Rev., 2005, 49, (3), 110
14 D. Miller, T. Keraan, P. Park-Ross, V. Husemeyer, A. Brey,
I. Khan and C. Lang, Platinum Metals Rev., 2005,
49, (4), 174
15 U. E. Klotz and T. Drago, The Role of Process Parameters
in Platinum Casting, in The Santa Fe Symposium on
Jewelry Manufacturing Technology 2010, ed. E. Bell,
Proceedings of the 24th Symposium in Albuquerque,
New Mexico, USA, 16th19th May, 2010, Met-Chem
Research Inc, Albuquerque, New Mexico, USA, 2010,
pp. 287326
16 J. C. McCloskey, Microsegregation in Pt-Co and Pt-Ru
Jewelry Alloys, in The Santa Fe Symposium on Jewelry
Manufacturing Technology 2006, ed. E. Bell, Proceedings
of the 20th Symposium in Nashville, Tennessee, USA,
10th13th September, 2006, Met-Chem Research Inc,
Albuquerque, New Mexico, USA, 2006, pp. 363376
17 J. Fischer-Bhner, Computer Simulation of Investment
Casting, in The Santa Fe Symposium on Jewelry
Manufacturing Technology 2006, ed. E. Bell, Proceedings
of the 20th Symposium in Nashville, Tennessee, USA,
10th13th September, 2006, Met-Chem Research Inc,
Albuquerque, New Mexico, USA, 2006, pp. 193216
18 M. Actis-Grande, L. Porta and D. Tiberto, Computer
Simulation of the Investment Casting Process: Widening of
the Filling Step, in The Santa Fe Symposium on Jewelry
Manufacturing Technology 2007, ed. E. Bell, Proceedings
of the 21st Symposium in Albuquerque, New Mexico,
USA, 20th23rd May, 2007, Met-Chem Research Inc,
Albuquerque, New Mexico, USA, 2007, pp. 118
The Authors
Ulrich E. Klotz graduated from the
University of Stuttgart, Germany, as a
Diploma Engineer in Physical Metallurgy
and has a PhD in Materials Science from
ETH Zrich, Switzerland. He is Head of the
Department of Physical Metallurgy at the
Research Institute for Precious Metals and
Metals Chemistry (FEM) in Schwbisch
Gmnd, Germany.
Tiziana Drago has a BSc in Materials
Engineering with specialisation in surface
treatments from the Politecnico di Milano,
Italy, and an MSc in Materials Science
from the University of Pisa, Italy. She works
in the Department of Physical Metallurgy at
the Research Institute for Precious Metals
and Metals Chemistry (FEM) in Schwbisch
Gmnd, Germany.
2011 Johnson Matthey